CN113898506B

CN113898506B - Super-pleated vehicle air filter

Info

Publication number: CN113898506B
Application number: CN202111369210.4A
Authority: CN
Inventors: S·威廉斯
Original assignee: K&N Engineering Inc
Current assignee: K&N Engineering Inc
Priority date: 2016-03-08
Filing date: 2017-03-08
Publication date: 2024-10-11
Anticipated expiration: 2037-03-08
Also published as: US11536231B2; CN113898506A; US20230123016A1; CN109475801B; KR20210121276A; EP3426376A1; US10563628B2; BR112018068219A2; CN109475801A; KR102439990B1; KR102306389B1; KR20180134881A; US20200158053A1; CA3017180A1; WO2017156155A1; BR112018068219B1; AU2023200921A1; EP3426376A4; AU2017231717A1; MX2018010911A

Abstract

An apparatus and method for an air filter configured to be mounted on an air inlet of an internal combustion engine is provided. The air filter includes a first end cap configured to couple with a base configured to support a conventional air filter and provide an interface between the conventional air filter and an air inlet. The relatively thicker filter media than conventional air filters is configured to remove particulate matter and other contaminants from the incoming air stream. The second end cap is configured to couple with a cap portion configured to secure the conventional air filter and base to the air inlet such that an incoming air flow is directed through the filter media. The air filter is configured to be installed in place of a conventional air filter without requiring modification of the base and cover portions.

Description

Super-pleated vehicle air filter

The application is a divisional application of a Chinese application patent application with the application number 201780028342.6 and the application date 2017, 3, 8 and entitled "ultra-pleated vehicle air Filter".

Cross reference to related applications

The present application claims the benefit of priority from U.S. patent application Ser. No.15/453,353, filed on 8 days 3 and 2017, and U.S. provisional application Ser. No. 62/305,432, filed on 8 days 3 and 2016.

Technical Field

The field of the present disclosure relates generally to filtration devices. More particularly, the field of the invention relates to an apparatus and method for an air filter configured to be mounted on an air inlet of an internal combustion engine.

Background

Air filters designed to remove particulate matter from an air stream are generally devices that include fibrous materials. These fibrous materials can remove solid particulates such as dust, pollen, mold, and bacteria from the air stream. Air filters are used in applications where air quality is important, notably in building ventilation systems and with engines.

Air filters may be used in automobiles, trucks, tractors, locomotives and other vehicles that use internal combustion engines. The air filter may be used with a gasoline engine, a diesel engine, or other engines that utilize fossil fuels or other combustible materials. The air filter may be used with other types of engines in which combustion is intermittent (e.g., four-stroke and two-stroke piston engines) and in which air is continuously drawn in so that combustible materials may be combusted. For example, air filters may be used with some gas turbines. The filter may also be used with an air compressor or in other devices that draw in air.

The filter may be made of pleated paper, foam, cotton, spun glass fiber, or other known filter materials. In general, air filters used with internal combustion engines and compressors tend to be constructed from any of paper, foam, or cotton filters. Some filters use oil sumps. Air filters for internal combustion engines prevent coarse particulate matter from entering the cylinders of the engine, where it can lead to mechanical wear and oil contamination. In many fuel injection engines, flat pleated paper filter elements may be used. The filter is typically placed in a plastic box that is connected to the throttle body with tubing. Vehicles using carburetor or throttle body fuel injection typically use a cylindrical air filter positioned above the carburetor or throttle body.

Air filters may also be used to filter cabin air, such as air in vehicles (e.g., automobiles, trucks, planes, buses, trains, tractors, etc.). These air filters may typically be pleated paper filters, wherein outside air is passed through the filter before entering the passenger compartment of the vehicle. Some of these filters are rectangular and similar in shape to combustion air filters.

Drawings

The accompanying drawings refer to embodiments of the present disclosure, in which:

FIG. 1 is a perspective view illustrating an exemplary embodiment of a filtration system including an air filter according to the present disclosure;

FIG. 2 is a perspective view illustrating an exemplary embodiment of an air filter according to the present disclosure;

FIG. 3 is a perspective view showing a conventional air filter held between a base portion and a cover portion; and

Fig. 4 is a perspective view showing the conventional air filter shown in fig. 3 without a base portion and a cover portion.

While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood that the invention is not to be limited to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure.

Detailed Description

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, to one of ordinary skill in the art that the invention disclosed herein may be practiced without these specific details. In other cases, specific numerical references such as "first filter" may be made. However, specific numerical references should not be construed as literally sequential order, but rather as "first filter" being different than "second filter". Therefore, specific details set forth are merely exemplary. The specific details may be different from, and still be contemplated to be within, the spirit and scope of the present disclosure. The term "coupled" is defined as connected to an element either directly or indirectly to the element through another element. Furthermore, as used herein, the terms "about," "approximately," or "substantially" as used in any numerical value or range mean a suitable dimensional tolerance that allows a portion or collection of components to be used for their intended purpose as described herein.

In one embodiment, an air filter configured to be mounted on an air inlet of an internal combustion engine is disclosed, comprising: a first end cap configured to couple with a base configured to support a conventional air filter and provide an interface between the conventional air filter and an air inlet, the base including an inlet receiver configured to receive the air inlet; a filter medium of the air filter configured to remove particulate matter and other contaminants from an incoming air stream; and a second end cap configured to couple with a cap portion configured to secure the conventional air filter and base to the air inlet such that an incoming air flow is directed through the filter media.

In another embodiment, the air filter is configured to be installed in place of a conventional air filter without requiring modification of the base and cover portions. In yet another embodiment, the filter media is relatively thicker than that of a conventional air filter.

In one embodiment, the wire support is incorporated into the filter media and is configured to provide strength and durability to the filter media. In another embodiment, the filter media is retained between the first and second end caps.

In one embodiment, the first end cap includes a recess configured to receive a peripheral edge of the base, thereby facilitating coupling of the air filter with the base. In another embodiment, the second end cap includes a recess configured to receive a peripheral edge of the cap portion to facilitate coupling the air filter with the cap portion. In yet another embodiment, the first and second end caps are constructed of a deformable material strong enough to support the filter media.

In one embodiment, the filter media is comprised of paper, foam, cotton, spun glass fiber or other known filter materials, woven or nonwoven materials, synthetic or natural, or any combination thereof. In another embodiment, the filter media is pleated or otherwise shaped or contoured to increase the surface area for delivering the air flow to be cleaned. In yet another embodiment, the filter media includes oil to enhance the air cleaning performance of the filter media.

In general, the present disclosure describes an apparatus and method for an air filter configured to be mounted on an air inlet of an internal combustion engine. The air filter includes a first end cap configured to couple with a base that is configured to support a conventional air filter and provide an interface between the conventional air filter and an air inlet. The relatively thicker filter media than conventional air filters is configured to remove particulate matter and other contaminants from the incoming air stream. The filter media may be constructed of paper, foam, cotton, spun glass, or other known filter materials, woven or nonwoven materials, synthetic or natural, or any combination thereof. In some embodiments, the filter media is pleated or otherwise shaped or contoured to increase the surface area for delivering the air flow to be cleaned. Preferably, the filter media includes oil to enhance the air cleaning performance of the filter media. The second end cap is configured to couple with a cap portion configured to secure the conventional air filter and base to the air inlet such that an incoming air flow is directed through the filter media. In some embodiments, the wire support is incorporated into the filter media and is configured to provide strength and durability to the filter media. The air filter is configured to be installed in place of a conventional air filter without requiring modification of the base and cover portions.

Although embodiments of the present invention may be described and illustrated herein as a cylindrical air filter, it should be understood that embodiments of the present invention are not limited to the exact shape illustrated, but may include a wide variety of generally cylindrical shapes, generally circular, oval, rounded, curved, conical, or other closed peripheral shapes that provide a relatively large surface area in a given volume of the filter. Furthermore, embodiments as described herein are not limited to use as internal combustion engine filters, but may have applicability in other filtration systems where large volumes of air need to be treated.

Fig. 1 illustrates an exemplary embodiment of a filtration system 100 including an air filter 104 according to the present disclosure. The filter system 100 is configured to be mounted on an air inlet of an internal combustion engine. In the embodiment shown in fig. 1, the air filter 104 includes a filter media 108 held between a base 112 and a cover 116. The base 112 and cover 116 are preferably constructed of materials that are durable and resistant to high temperatures sufficient to maintain their configuration when coupled with the air inlet of an engine during installation and operation. As best shown in fig. 2, wherein the base 112 and cover 116 are removed from the air filter 104, the filter media 108 circumferentially surrounds the interior chamber 120 such that the filter media 108 creates an outer periphery of at least a portion of the chamber. The external cross-sectional shape of the air filter 104 may be generally circular, oval, or otherwise shaped to increase the surface area available for the air flow passage for a given volume. The shape may be uniform along the longitudinal length, or may vary along the longitudinal length. In some exemplary embodiments, the outer profile may taper along the longitudinal length from one end to the other.

The filter media 108 provides a region to transport the air stream and capture particulates and other contaminants flowing with the air stream. The filter media 108 may be constructed of paper, foam, cotton, spun glass, or other known filter materials, woven or nonwoven materials, synthetic or natural, or any combination thereof. The filter media 108 may be pleated or otherwise shaped or contoured to increase the surface area for delivering the air flow to be cleaned. The length of the filter media 108 in the circumferential direction may be generally longer than the circumference of the air filter 104 such that the surface area of the filter media 108 is greater than the contour surface area of the air filter 104.

The base 112 is generally configured to support the air filter 104 and provide an interface between the air filter 104 and an air inlet of the engine. The base 112 includes an inlet receiver (not shown) configured to receive an air inlet of an engine. The cover 116 is configured to secure the filter media 108 and the base 112 to an air inlet of an engine such that air is drawn through the filter media 108 into the interior chamber 120 of the air filter 104 and then conducted through the inlet receiver into the air inlet of the engine. As described, the inlet receiver of the base 112 has a configuration adapted to receive an air inlet of an engine. For example, the inlet receiver may include any of a variety of ridges or raised portions to optimally engage the air inlet of the engine. Further, it is contemplated that the inlet receiver may be secured to the air inlet by any of a variety of suitable mechanical fasteners. It should be appreciated that the particular configuration of the inlet receiver depends on the particular make and model of engine that is to utilize the air filter 104, and thus a wide variety of configurations may be incorporated into the air filter 104 and the base 112 without departing from the scope of the present disclosure.

As best shown in fig. 2, the air filter 104 includes filter media 108 held between end caps 124 and 128. The end caps 124, 128 may be rubber or plastic or other deformable material strong enough to support the filter media 108. For example, one or both of the end caps 124, 128 may be molded polyurethane, foamed polyurethane, or polyurethane elastomer, and/or may include a steel or aluminum infrastructure. In the exemplary embodiment shown, an elastomer molded polyurethane is used to provide additional rigidity and a strong exterior seat for filter media 108. For reusable filters, molded elastomers are preferred over foam to reduce degradation during air filter cleaning.

In some embodiments, wire supports may be incorporated into the filter media 108 to provide additional strength and durability to the air filter 104. As such, the wire support is preferably retained by the end caps 124 and 128 along with the filter media 108. It will be appreciated that the filter media 108 and wire support may be secured to the end caps 124, 128 by any of a variety of fasteners (not shown). In some embodiments, the end caps 124, 128 may be molded to the wire support of the filter media 108. In some embodiments, a portion of each end cap 124, 128 may be crimped around its peripheral edge such that it folds over the wire support and filter media 108 of the air filter 104 and retains the wire support and filter media 108 of the air filter 104. Any of a variety of fastening means may be practiced for attaching the filter media 108 and wire support to the end caps 124, 128 without departing from the spirit and scope of the present disclosure.

Fig. 3 is a perspective view showing the base 112 and the cover 116 mounted on a conventional air filter 132. Fig. 4 is a perspective view showing a conventional air filter 132 without the base 112 and the cover 116. As best shown in fig. 3, the cover 116 includes a peripheral edge 136 configured to retain an end cap 140 of a conventional air filter 132. Similarly, the base 112 includes a peripheral edge 144 configured to retain an end cap 148 of a conventional air filter 132. It will be appreciated that the peripheral edges 136, 144 serve to retain the conventional air filter 132 between the cover 116 and the base 112 such that when the filter 132 is installed onto the air inlet of an engine, air flow is drawn through the filter media 152. Fasteners 156 are used to retain the conventional air filter 132 between the cover 116 and the base 112 and thus mount to the air inlet of the engine. In the illustrated embodiment, the fasteners 156 are simply holes provided in the center of the cover 116, allowing bolts to extend from the air inlet up through the interior chamber of the air filter 132. As will be appreciated, a suitably sized nut may be tightened onto the bolt, thereby mounting the conventional air filter 132 to the air inlet of the engine.

When comparing the conventional air filter 132 shown in fig. 3 with the air filter 104 shown in fig. 1, it will be observed that the end caps 124, 128 extend beyond the peripheral edges 136, 144, respectively. As best shown in fig. 2, end cap 124 includes a recess 160 configured to receive peripheral edge 136. Although not shown, the end cap 128 includes a recess that is substantially similar to the recess 160 and is configured to receive the peripheral edge 144. As will be appreciated, the filter media 108 is relatively thicker than the filter media 152 of the conventional air filter 132, and accordingly, the end caps 124, 128 are relatively wider in the radial direction than the end caps 140, 148 of the conventional filter 132. Accordingly, while the base 112 and cover 116 are sized to accommodate a conventional air filter 132, the recess 160 in the end caps 124, 128 advantageously facilitates coupling a relatively thicker air filter 104 with the base 112 and cover 116. Accordingly, it should be appreciated that the air filter 104 of the present disclosure may be installed in place of the conventional air filter 132 without any need to alter the base 112 and cover 116.

It is envisioned that a user of the air filter 104 may periodically clean the filter media 108 rather than replace the air filter 104 as is typical with conventional air filter systems. In some embodiments, the method for cleaning the filter media 108 includes removing the cover 116 from the filtration system 100, removing the air filter 104 from the base 112, inserting a water hose into the interior chamber 120 of the filter, and spraying water to flush contaminants from the filter media 108. In some embodiments, the method for cleaning the air filter 104 includes using a high pressure air hose instead of a water hose. In some embodiments, the method for cleaning the air filter 104 includes spraying water onto the exterior of the filter media 108 such that water and contaminants are discharged from the exterior of the filter media 108. Other cleaning methods will be apparent to those skilled in the art without departing from the spirit and scope of the present disclosure.

As discussed above, the wire support may be coupled with the filter media 108 to provide additional strength and durability to the air filter 104. The wire support helps to periodically clean and reuse the air filter 104 rather than discarding the filter after each application. In some embodiments, the filter media 108 may be positioned between the wire support and one or more layers of reinforcing material. For example, the wire support may include wire mesh screens positioned on the outer and inner surfaces of the filter media 108. In some embodiments, the wire mesh may comprise powder coated aluminum mesh wires that are co-pleated with the filter media 108 to strengthen the air filter 104. In some embodiments, the inner surface of the filter media 108 may include stronger mesh reinforcement, similar to those incorporated into diesel filter applications. In some embodiments, additional or alternative reinforcements may be provided, as will be apparent to those skilled in the art.

In the embodiment of the air filter 104 shown in fig. 1 and 2, the base 112 has a diameter substantially equal to the diameter of the cover 116. However, in some embodiments, the base 112 may have a size that is larger than the size of the cover 116. It should be appreciated that the air filter 104 of the present disclosure is not limited to the exact shape shown in fig. 1 and 2, but may include a wide variety of generally cylindrical shapes, generally circular, oval, rounded, curved, or other closed peripheral shapes that provide a relatively large surface area of the filter media 108. In some embodiments, the filter media 108 may include various heights in addition to those shown in fig. 1 and 2, as well as various tapers.

While the invention has been described in terms of specific variations and illustrative figures, those of ordinary skill in the art will recognize that the invention is not limited to the variations or figures described. Furthermore, where the methods and steps described above indicate that certain events occur in certain orders, those of ordinary skill in the art will recognize that the ordering of certain steps may be modified, and that such modifications are in accordance with the variations of the invention. Additionally, certain steps may be performed concurrently in a parallel process where possible, or sequentially as described above. To the extent that modifications of the invention are within the spirit of the disclosure or are equivalent to the inventions as found in the claims, this patent is also intended to encompass such modifications. Therefore, the present disclosure should be understood as not limited to the particular embodiments described herein, but only by the scope of the appended claims.

Claims

1. An air filter for an internal combustion engine, comprising:

a first end cap for receiving a peripheral edge of a base configured to couple a conventional air filter with an air inlet;

a filter medium configured to remove contaminants from the air stream; and

A second end cap for receiving a peripheral edge of a cap portion configured to secure a conventional air filter to the air inlet;

wherein the first end cap includes a recess for receiving the peripheral edge;

wherein the second end cap includes a recess for receiving the peripheral edge.

2. The air filter of claim 1, wherein the first end cap is wider in a radial direction than a first end cap comprising the conventional air filter.

3. The air filter of claim 1, wherein the second end cap is wider in a radial direction than a second end cap comprising the conventional air filter.

4. The air filter of claim 1, wherein the filter media includes a series of pleats disposed between the first end cap and the second end cap.

5. The air filter of claim 4, wherein the pleats are deeper than pleats comprising the conventional air filter.

6. The air filter of claim 1, wherein the filter media comprises any of: paper, foam, cotton, spun glass fibers, other known filter materials, and any combination thereof.

7. The air filter of claim 1, wherein the filter media comprises a woven or nonwoven material.

8. The air filter of claim 1, wherein the filter media comprises a synthetic or natural material.

9. A method for an air filter for an internal combustion engine, the method comprising:

Connecting a first end cap with a base configured to couple a conventional air filter with an air inlet;

connecting a second end cap with a cap portion configured to secure a conventional air filter to the air inlet; and

Securing the cover portion to the second end cover such that an air stream is drawn through the filter media;

Wherein coupling the first end cap includes engaging a peripheral edge of the base with a recess including the first end cap, and wherein coupling the second end cap includes engaging a peripheral edge of the cap with a recess including the second end cap.

10. The method of claim 9, wherein securing the cover includes securing a suitably sized nut to a bolt configured to mount the conventional air filter to an air inlet.

11. The method of claim 10, wherein tightening the appropriately sized nut includes retaining an air filter between the cover and the base.

12. A method for an air filter for an internal combustion engine, the method comprising:

Constructing a first end cap for receiving a peripheral edge of a base configured to couple a conventional air filter with an air inlet;

constructing a second end cap for receiving a peripheral edge of a cap portion configured to secure a conventional air filter to the air inlet; and

Disposing filter media between the first end cap and the second end cap;

Wherein configuring the first end cap includes forming a recess for receiving a peripheral edge of the base;

Wherein configuring the second end cap includes forming a recess for receiving a peripheral edge of the cap portion.

13. The method of claim 12, wherein configuring the first end cap includes making the first end cap wider in a radial direction than a first end cap that includes the conventional air filter.

14. The method of claim 12, wherein configuring the second end cap includes making the second end cap wider in a radial direction than a second end cap that includes the conventional air filter.

15. The method of claim 12, wherein disposing the filter media comprises disposing a series of pleats including the filter media between the first end cap and the second end cap.

16. The method of claim 15, wherein arranging the series of pleats includes forming pleats deeper than pleats comprising the conventional air filter.

17. The method of claim 16, wherein forming the pleats comprises forming pleats in a wire support that is incorporated into a filter media.